Composite upholstery rope or cord and the method of making same



Feb. 21, 1928.

' R. F. SMITH COMPOSITE UPHOLSTERY ROPE QR (iORD AND THE METHOD OFMAKING SAME Fiied May 18, 1927 RNEY.

Patented Feb. 21, 1928.

UNITED STATES PATENT OFFICE.

RAY F. SMITH, OF CORTLAND, NEW YORK.

COMPOSITE UPHOLSTERY ROPE OR CORD AND THE METHOD OF MAKING SAME.

Application filed MaylB,

My invention relates to cords, lines and. the like stranded threads oryarns primarily composed of fibrous material, and more particularlypertains to means for reenforcing that class of loosely woven strandswhich owing to their inherently stretchy nature, have heretofore provendeficient and not altogether serviceable when used under occasionalheavy strains for the purposes herein intended. I I

It is therefore contemplated to fortify upholstery ropes of theconventional all-yarn type-againstobjectionable sagging by resorting toa supplementary embedded ligament or core element extending centrallythrough the rope filler. lhis core made up of, relatively inextensiblematerial, imparts this unyielding characteristic to the adjoiningfibrous filler medium andthereby augments the 'longitudinalrigidityofthe rope structure ;as a whole. .Said ligament is intended I toeffectively meetthe major portion of load All that may be carried by mycomposite rope and thus prevent the surrounding filler body frombecoming loaded beyond its limit of re siliency or yield point; it isfurther preferred to resort to relatively low flexural strength for thecore element in order to give ample pliability and obviate retentionofany fixed contour when bent transversely.

The objectof the present invention is-to devise-a substantiallynon-yielding and durable rope capable of taking up considerablelengthwise strain and to provide improved means for economically makingcomposite ropes, especially reenforced upholstered ropesof differentsizes, styles and lengths such as find a rather wide application in theheld of vehicle robesupporting rails, seat hangersand door grip cordsalso in rail ropes for enclosing-gangways, stair cases, exhibitionspaces and similar decorative or utilitarian purposes. I Rope of thiskind is commonly cut into comparatively short lengths and suspendedbetween suitable supports or posts; a further object lies in de visingeffective means for the securement of my non-stretchable core elementtosuch supports whereby undue-sag on part of the composite rope may bechecked-orretarded even when subjected .to abnormal usa'geor strain.

A still further object is to provide for building up afibrous fillermedium adapted to neatly conceal and gripsaid reenforcing core, and inturn to surround this smoothly rounded filler contour with a decorative1927. Serial No. 192,472.

outer sheath that serves to adorn my compos-.

ite rope. In addition, means have been devised for neatly trimming theends of such rope sections with appropriate terminal fittings that aresecurely bonded to the component rope elements and adapted to transmitthe full rated load Without diminution of rope capacity.

An improved rope of the indicated character lends itself to many uses,and as exem" plified by the cited robe rail for automobiles, myreen-forced rope when hung and transyersely loaded with lap robes orheavy wearing apparel is still capable of withstanding the resultantstrain without suffering a per-' niciousset or permanent stretch. Roberails are not infrequently subjected to unusual stralns and especiallywhen fashioned from conventional twisted rope, they tend to stretchprogressively under repeated overloads. Eventually the resulting sag ofsuch all-yarn ropes is likely to become augmentfed to such extent thatthe suspended gartrative embodiment of my invention; like characters ofreference indicate like-parts in the several views and in which drawing:

Fig. 1 is a side elevation showing my inextensible rope applied as arobe rail located at the backof an automobile seat, the opposite ropeends being for convenience shown as equipt withtwo different styles ofbracket attachments.

Fig. 2 is a broken perspective view of one type of core element that maybe embedded within the filler mediumof a robe rail such as shownin .Fig.1.

Fig. 3 represents a'enlarged detail of the left-hand terminal pieceas-taken along line 33 of Fig. 1 while Fig. 4 is a similar detail of themodified right-hand piece taken along line 4-4.

Fig. 5 depicts a series of linked or inter- Reference is had to theaccom-' connected core elements of the type indicated in Fig. 2 andwhich chain of links may be covered with a fibrous filler medium bymeans of a continuous laying process. 1

Fig. 6 shows still another style of rope terminal fitting which,likewise permits the.

reenforcedrope to be fabricated continuously but differs somewhat fromthe showing of Fig. 5 in that a perforated band or tape of relativelythin metal is here utilized as the core elements, the terminal fittingsbeing anchored thereto after cutting the rope into finite lengths.

Fig. 7 is a transverse section of said core tape as taken along; line 77of Fig. 6.

Fig. 8 shows a fragmentary sectional view similar to Fig. 4i except thata crocheted fab- 'ric hood is here resorted to for trimming thepreferably embedded near the center region of its surroundingstretchable filler or body medium 5. Said core may comprise one or moreend to end linked elementsof which one such may be formed into arelatively flexible cable section interposed between suitable terminal.pieces as indicated in Fig. 2. v Said intermediate section such as r maybe made up of a plurality of metallic stranded wires, flat tape'or thelike'ligament possessing a sufficiently high coetlicient of rigiditytoenable a suspended or otherwise hung cable of this kind to carry itsanticip ated load without appreciable elongation or permanent stretch.

The cross-sectional area of such cable means M is preferably kept smallrelative to the exterior of the pliable filler 5 in order not to undulystifi'enthe rope transversely at least in one direction and thus affordsuiticient pliability to assume a graceful catenary or chain-likecurvature when looped or freely suspended between two closely spacedsuppo'rtmembers such as the brackets 2 and 3 of Fig. 1

In the particular core embodiment shown in Fig. 2, relatively stiffterminal pieces are provided to reenforce the end regions of theflexible cable 4A and said pieces are here fashioned into short metallicextension straps or keepers 7 and 8. Each suchstrap may be provided witha series of. spaced holes therethrough such as 7A, 7B, and 7G,

and the respective ends of the cable core portion 4A maybe secured tosaid comple mentary straps in any suitable manner, for instance by theeye end means having the return loop end secured upon itself by tubularclamps 9'as indicated. The purpose of said sraps is to provide foramanipulative member adapted to reenforce the somewhatfragile strandedcable lA and it will be observed that said straps together with theintermediate cable section are intended to form an embedded ligamentthat afiords a continuous metallic tie connection capable of beingfirmly anchored to the respective rope end supports. 7 r.

In order to facilitate the manufactureof my composite rope, a pluralityof core elements similar to those shown in Fig. 2 and of anypredetermined sectional length such as L, L etc., may be coupledtogether by. means of detachable core links (designated as 10, 10 etc.)to form a chain of linked members in the manner indicated in Fig. 5 butas will appear hereinafter,'such a continuous core may also. be made upin other ways. The formation of a relatively'iong core means thatpossesses the described characteristics, constitutes theffirst step inmy method of making reenforceol ropes. I

A core chain or other virtually continuous core medium havinganindefinite length but at least as long as the shortest desired singleunit measurement L, L, etc., may most readily be carried up and made tofeed through the former of a suitable braiding machine or the like. Thesecond step in mymethod consists iii-providing forbrai'din'g, orotherwise laying a tiller 5 upon and-lengthwise of the aforesaid linkedcore'elements, it be ing understood that the term laying of the filleris herein used in its broadest sense to include any suitable methodadapted to pack the filler yarn around the core member. This filler maycomprise a'plurality of comparatively loosely woven superimposed layersof yarn or other similar filler'body material,

preferably of an inherently pliable fibrous and stretchy character suchas will freely accommodate itself to any sharp deflection on part of themore rigid core member. The purpose of said body medium is to providefor an enlarged and substantially uniform periphery about saidintermediate ligaments 4A together with. the adjoined straps 7 and 8 andthereby form a suitable smooth foundation for the finishing covering 5A.This filler 5 further provides for a protective cushioning mediumbetween said outer sheath and the concealed core element; itnot onlymaintains initial fullness but keeps said sheath in a perfect sleekcondition and prevents collapse or peripheral distortion thereof. I v r7 When the cited braiding operation is used to lay the rope filler,thepartially completed rope may be reeled between successive layers andthis operation repeated until the desired body thickness has beenreached; if-desired this operation may also bev effected byrunningmyrope ligament through a seriesof machines, each of which braids one ormore such layers. It is emphasized that my virtually endless core linkmethod greatly expe- 'dites and otherwise effectively reduces the costof making such composite ropes.- In resortingto the type of enlargedends for the twisted or plied fashion other than braiding.

The outer or last of such filler layers is here shown as worked up intoa seamless finishing sheath 5A, and this is preferably woven fromvariously colored plied or braided yarns such as rayon or the like,adapted to decorate and enhance the salability of my upholstery rope. Asapplied to automobile robe rail purposes, it is advantageous to finishsuch textile covering into an anti-slip or friction surface adaptedtoprevent the suspended apparel from slipping off while sub jectcd tojolting or car vibration.

Regarding the intermediate strap hole 7B, one or more such may beutilized to receive suitable pronged cleats or filler bonds such as 12,which securement obviates slipping of the filler along the coreligament. As shown in Fig. 3, the rivet cleat 12 may comprise an Lshaped staple that is driven through said hole 7B as indicated in dottedlines, whereupon the projecting unbent leg thereof may be clinched downin place as shown in full lines for establishing a tighter grip betweenthe strap 7 and its surrounding filler 5. This cleat is preferablyinsertedprior to weaving the finishing sheath 5A so as not to deface theexterior of the rope; any suitable filler gripping means projectingoutwardly from the core element will answer said interloeking purposesand any such bond may be 'ap-' n plied either before or after wrappingthe filler about the core element.

As a third step in my method of making said reenforccd rope,this is nowcut into any desired fixed length to meet requirements. in the event alinked core should be used as indicated in Fig. 5, the severing of myrope of indefinite length is intended to occur in the region of theseparable core links 10, 10, etc. which links may thereupon bediscarded.

l Said relatively vlong rope is thereby divided into a .series of unitor sectional ropes each having a predetermined but selective length L,L, etc., andit now merelyremains .to trim the complementary rope ends inone of several alternative ways.

Referring first to Fig. 3, the keeper strap 7 is here shown as a flatterminal piece having its surrounding filler trimmed back to partiallyexpose the free strap end for attachment purposes. An apertured cap orferrule such as 6 may be sprung over and cemented to the end of thesheath 5A so as to incase and prevent the rope end from be coming frayedor unraveled; if preferred, the same end may be attained by trimming thetiller end by means of a cord binding. The exposed projection of thestrap 7 may thereuponbe fitted into the socket 2A of the support bracket2 and a Wedge pin 5213 entered and driven through the outermost straphole 7 C to interlock and firmly anchor the rope core into said bracket.Either of such :robe rail fastenings may however be 1 made detachable tofacilitate placing garments thereon. 1

The fourth step in my method resides in providing for suitably anchoringthe rope 7 ends to enable said core ligament to give better support tothe surrounding fibrous filler medium but this particular step is op-'tional and does not represent an indispensable feature in the making ofmy composite rope.

Referring now to Fig. 4, it will be seen that this style of terminalstrap 8 is essentially similar to the previously described strap 7,except that the aperture 7A is now replaced by a bent up eye end 8C;this alternative method may in turn engage the endless link or ring 313as mounted through the hook 3A of themodified bracket 3. A

ferrule 6 may again be resorted to and this is here provided with anapertured cap portion adapted to slip over the strap eye end 8C. r 1

Regarding a further modification as shown .in Fig. 6, a metal tape orother strip of non-stretchable ligament 4A is indicated which may beprovided with a series of closely spaced perforations 7 C" to serveas'the integral equivalent of the aforesaid core chain links, and afiller medium 5 together with a finishing sheath 5A may again be woventhereon in the manner previously described.

Said tape is preferably kept amply long while passing through thebraiding machine to allow of fabricating the rope in easily workablestocklengths which may subsequently be cut off into any shorter lengthswithout having to predetermine the desired finite len hs.

' The filler adjacent to the respective rope ends may then be cut back ashort distance with respect to the severed tape ends 4A so as toexposeone of the perforations such as 70". In this instance, it may alsobe expedient to alter the support bracket somewhatand provide. one suchdesignated as 11, having a tubular socket or housing portion 11A equiptwith an inwardly disposed flange 11B andan aperture 11C therefor adaptedto snugly embrace the rope sheath A.

When resorting to the style of terminal that is shown in Fig. 6, it ispreferred to pass the rope end through the bracket aperture 11C andapply a slightly modified cap or ferrule such as 6A which is providedwith an outwardly flared flange 6A adapted to abut the reversed flange1113 in the manner I shown. A bent up pin 2B engaging the tape aperture7C serves to lock the ligament into the bracket 11. Should it be desiredto bond said tape 4A into the filler -5, this may be accon'lplished bythe use of one or more cleats such as 12A which are here concealedWithin the bracket housing and intended to pass through one of said tapeperforations. OW:

ing to the pliable nature of my composite rope, its end may be drawnthrough the aperture 11C to more conveniently secure the Iliave providedfor a novel and effective method for the rapid production of a compositerope and oneembodying either an interconnected or continuousinextensible core ligament that extends longitudinally through thesurrounding resilient filler medium and serves as an effectivereenforcement and protection for the latter. Said filler may be made upof any fibrous substances having an inherently stretchy and pliablecharacter and which of itself does not possess sufficient rigidity tosustain heavy strains without undergoing an ultimate permanent sag; assuch'it provides for a suitable cushioning body and takes out anyunevenness in the contour ofthe core element. Furthermore, mywell-rounded rope structure is finished with a neat seamless outercovering to make it entirely suitable applied to fine upholstery orother trimming purposes. In addition, my incorporated ligament is kepttransversely flexible and because this core-is anchored directly to therope support, it is adapted to carry the major portion of any reasonableload that may be exerted thereon, all without abnormal elongation orallowing undue capable'of retaining its shape and without tendency topermanently. stretch the loosely woven fillermedium even under adverseload conditlons'or eopard1ze the initial looseness of knitand fluffyluster of'my sheath covering. I i

- ;While specific embodiments of my invention have been set forth indetail, it is to be understood that the herein described structuresmayreadily be modified to meet differing. conditions of use andmanufacture, such for instance as the making up of my composite rope inpredetermined short lengths rather than in the indicated endlessfashion, andthat various changes-in the details of my method ma beresorted to, all Without departing from the spirit and scope of myinvention as more particularly pointed out in the appended claims.

Iclaim f l.-The method of making flexible compositeropes or the likecomprising a core ligament means that is substantially inextensiblelongitudinally but kept flexible transversely and which ligament isembedded lengthwise of a relatively stretchy filler'medium, said methodconsisting in the following steps, viz: firstly, forming a core ligamentmeans comprising a series of finite cable lengths each having theirrespective ends reenforced by a relatively rigid keeper strap and whichstraps are initially coupled together into an indefinite length;secondly,

repeatedly carrying said ligament through a braiding machine or machinesto lay thereon a series :of superimposed layers of braided yarn strandsadapted to build upfia pliable filler body andfila'stly, severing todivide said composite rope into finite sectional lengths each providedwith reenforced' ends. -2.,The method of making flexible composite ropesor the like comprising acore ligament .means that is substantiallyinextensible longitudinally but kept flexible transversely and whichligament is embedded lengthwise of a relatively stretchy;

filler medium, said method consisting in the" following steps, viz:firstly, forming a continuous core ligament means having enlargedreenforced end portions vthat are adjoined to a relatively flexibleintermediate portion; and lastly, laying fibrous strands between saidenlarged end portions untilsaid ligament assumes a substantially evensize and thereupon superimposing layers of such strands extendingthroughout the length of said ligamentt'o build up a filler body ofsubstantially uniform periphery embracing a. cross-section areamaterially larger than thatjof the core ligament.

3. Themethod' of. making flexible com posite ropesor the like comprisinga core ligament means that is substantially inextensiblo longitudinallybut kept flexible transversely and which ligament is embedded lengthwiseof a relatively stretchy filler medium, said method consisting in thefollowing steps, vizz'firstly, forming a core ligament means comprisinga flexible cable length having each of its ends reenforced by arelatively rigid keeper strap; secondly, laying thereon: a filler bodycomposed of fibrous strands of a diflerentmaterial from that used informing said ligament and which filler is bonded to said ligament toprevent slippage therebetween, and lastly, braiding a tubular finishingcover over both said filler body and the aforesaid bonding means. 7 a

a. The method of making flexible composite ropes or the like comprisinga core ligament means that is substantially inextensible longitudinallybut kept flexible transversely and which ligament is embedded lengthwiseof a relatively stretchy filler medium, said method consisting in thefollowing steps, viz: firstly, forming a core ligament means comprisinga flexible cable length having each of its ends reenforced by arelatively rigid keeper strap provided with a plurality of spacedperforations; and lastly, laying thereon a body of braided fibrousfiller strands adapted to accommodate itself to lateral flexur'e on partof said ligament and bonding said body to the ligament by fullyconcealed means of the clinched staple type entered through one or moreof the aforesaid spaced perforations.

5. The method of making flexible composite ropes or the like adapted forsuspension between support means and which rope comprises a coreligament kept substantially inextensible longitudinally but flexibletransversely and which ligament is embedded lengthwise of a relativelystretchy filler medium, said method consisting in the following steps,viz: firstly, forming a core ligament means comprising a flexible'cablelength having each of its ends reenforced by an apertured relativelyrigid keeper strap; secondly, laying thereon a pliable filler bodycomposed of braided fibrous strands; and

lastly, anchoring said straps directly to the rope support by means ofthe respective strap apertures. 1

6. The method of making flexible composite ropes or the like adapted forsecurement to support means and which rope comprises a core ligamentkept substantially inextensible longitudinally but flexible transverselyand which ligament is embedded lengthwise of a relatively stretchyfiller medium, said method consisting in the fol lowing steps, viz:firstly, forming a core ligament means comprising a series of finitecable lengths each having their respective ends reenforced by a keeperstrap and which straps are initially coupled together into an indefinitelength; secondly, laying thereon a pliable filler body' composed offibrous strands thirdly, severing to divide said composite rope intofinite sectional lengths each provided with reenforced ends; and lastly,trimming back a terminal portion of one such length to expose theoutermost severed ligament end portion and prepare the same foranchorage to the ropesupport means.

7. The method of making flexible compos ite ropes or the like adaptedfor secure ment to support means and which rope comprises a coreligament kept substantially inextensible longitudinally but flexibletransversely and which ligament isv embedded lengthwise of a relatively,stretchy filler medium, said method consisting in the fol.-

lowing steps, viz: :firstly, forming a core ligament means comprising aflexiblecable length having each of its ends reenforced by a relativelyrigid keeper strap provided with a plurality of spaced perforations;secondly, laying thereon a pliable filler body composed of fibrousstrands and bonding said body to the ligament of staple means enteredthrough one of the intermediately disposed perforations of each strap;and l lastly, trimming back the respective filler body ends to exposethe respective terminal perforations for interlocked anchorage to thrope support means. I 8. The method of making flexible composite ropesor the like adapted for-securement to support means and which ropecomprises a core ligament kept substantially in extensiblelongitudinally but flexible transversely and which ligament is embeddedlengthwise of a relatively stretchy filler medium, said methodconsisting in the following steps, viz firstly, forming a core ligamentmeans comprising a series of finite cable lengths each having theirrespective ends reenforced by a relatively rigid keeper strap and whichstraps are initially coupled together into an indefinite length;secondly, laying thereon a pliable filler body composed of fibrousstrands; thirdly, severing said composite rope into finite sectionallengths; and lastly, trimming back the end portions of one such fillerbody length to expose its complementary ligament terminals and incasingeach of such filler body ends within an apertured ferrule-like hoodthrough which the respective terminal projectsfor anchorage to the ropesupport means. v V

9.'The' method of making flexible composite-ropes or the like adaptedforsecureembedded lengthwise of a relatively stretchy filler'medium,said method consisting in the ment to metal support means and which 2following steps, Viz: firstly, forming a definite length of metallicligament means comprising a flexible cable length having each of itsends reenforced by a relatively rigid keeper strap secondly, layingthereon a pliable filler body composed of fibrous strands; and lastly,attaching the respective ligament terminals to spaced rope support meansto constitute a continuous inextensible and direct metal tie connectiontherebetween adapted to take up the major portion of rope loading andobviate stretching of the filler medium beyond its yield point.

10. The method of making flexible composite ropes or the like adaptedfor securement to support means and Which rope comprises a core ligamentkept'substantially inextensible longitudinally but flexible trans-'versely and which ligament is embedded 20 lengthwise of a relativelystretchy filler medium, said method consisting in the following steps,viz firstly, formin a continu ous metallic ligament means of nite lengthcomprising an intermediary flexible cable portion Whose endsare adjoinedto keeper strap-like members of an enlarged crosssectional area adaptedtoreenforce the cable terminals for attachment purposes; secondly,laying thereon a pliable filler body composed of fibrous strands andWhich built-up body provides for smooth covering sheath 01 substantiallyuniform periphery adapted 1 to conceal the innermost end portions ofsaid interconnected straps; and lastly, preparing RAY F. SMITH.

